That 5/32" drill bit is dead nuts in the center of the stud.

 

So you can't use an abrasive disc and cut a slot in that? You might have to buy something better than what comes in the Dremel kit. And what kind of torch you using?

 

Thre pics are decieving. The bolt is recessesed about 1/4".

I cant cut a slot cause I will end up cutting the block.

And of course I only have a propane torch. I have read folks using the oxy torch and just melting the bolt out.

 

Propane torch won't work, not hot enough and melting it out is way too hot. What about drilling a series of almost joining smaller holes around the broken bit and using a punch. And if the bolt is sticking out the bottom any chance of getting a tool on it? If you can get something on it, with the proper heat it will come out.


And btw, if you use a small or worn disc you should be able to get some kind of groove cut. And cutting into the head slightly is not a big deal in that spot.

 

There's no cooling passages in that area of the block so what I'd do is cut a slot in the block to put a big enough slot in the stud and drill bit. Might need a carbide or diamond wheel to get the slot clean and true - can pick up a 1/2" - 1" wheel set fairly cheaply. Start the slot dead nuts center on the hole and the stud / drill bit. Once you're low enough into the block and stud lay down a healthy dose of PB Blaster or your favorite penetrating oil and let it sit for a couple hours. Then get in there with a drill / slot driver combination and it should back out fairly easy.

Once you have the stud / bit out clean the hole out good and build the slot back up with JB Weld. Try to build it up 1/32 - 1/16" into the hole to ensure it's sealed. Run through the hole with a tap to ensure the threads are true and you're done.

Granted you'll be cutting into the block so if you're unsure, don't do it....

 

First thanks for all yalls suggestions!

Before I start cuttin the block - the port to the left of the bolt in question on the head - it actually doesnt go into the plenum. The plenum is solid there. So any leaks from that area would be to the outside or inside.

Thats not the combustion chamber is it?

 

Here's what I would try

1 Get a center punch and try to start busting out the drill bit, it's brittle so it will break easy. If you get to a point that the center punch cant reach it any more use a pin punch to carry on. If you are lucky the flutes on the bit will open to you and you my be able to pick it out with needle nose pliers or just a pick or what ever works.
( WEAR SAFETY GLASS'S)

2 If above fails get a bunch of small drill bits and start to drill around the bit in the bolt go all the way though , punch out the drill bit. Re drill hole and then carry on with easy out.

3 Above all stay patient.

 

That's the head, not the block! And that port to the left is just a coolant port. I strongly recommend you do what you have to,to get that bolt out. You can use a 1 inch disc to cut a groove in that area and not even touch the gasket surface area.

 

Except for ( WEAR SAFETY GLASS'S) or glasses those two procedures have previously been suggested.

 

Oops sorry about that.
I can't tell from the pic but he may be able to; pull the water pump and timing chain cover and use a mini angle air drill to attack it from the bottom side.